Title of Invention	A FILTER FOR ANY KIND OF ITEMS THAT IS MADE OF TOBACCO AND A PROCESS FOR MANUFACTURING THE SAME
Abstract	Filter and process for producing filter (10,10') for articles of the tobacco processing industry. The filter includes at least one filter component of multiple-component fibers (12). The multiple-component fibers (12) have lengths shorter than a length of the filter (10,10'). The process includes producing a rod including at least one type of multi-component fibers (12) having lengths shorter than a length of the filter to be produced. Further, the multi-component fibers (12) have a casing (21). The process further includes heating the rod to a temperature above a melting temperature of the casing (21), and cooling the rod to a temperature below the melting temperature of the casing (21). The instant abstract is neither intended to define the invention disclosed in this specification nor attended to limited scope of the invention in any way.

Title of Invention

A FILTER FOR ANY KIND OF ITEMS THAT IS MADE OF TOBACCO AND A PROCESS FOR MANUFACTURING THE SAME

Abstract

Filter and process for producing filter (10,10') for articles of the tobacco processing industry. The filter includes at least one filter component of multiple-component fibers (12). The multiple-component fibers (12) have lengths shorter than a length of the filter (10,10'). The process includes producing a rod including at least one type of multi-component fibers (12) having lengths shorter than a length of the filter to be produced. Further, the multi-component fibers (12) have a casing (21). The process further includes heating the rod to a temperature above a melting temperature of the casing (21), and cooling the rod to a temperature below the melting temperature of the casing (21). The instant abstract is neither intended to define the invention disclosed in this specification nor attended to limited scope of the invention in any way.

Full Text	CIGARETTE FILTER AND PROCESS FOR MANUFACTURING THE SAME CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 102 17 410.5, filed on April 18, 2002, the disclosure of which is expressly incorporated by reference herein in its entirety. BACKGROUND OF THE INVENTION 1. Field of the Invention [0002] The present invention relates to a filter for articles of the tobacco processing industry, e.g., for cigarettes, that includes at least two filter components, in which one filter component is a sort of multiple-component fiber. The invention further relates to a process for producing a corresponding filter for articles of the tobacco processing industry, in particular for cigarettes. 2. Discussion of Background Information [0003] A process for producing a filter mass, e.g., for cigarette filters, is known from German Patent Application No. DE 30 28 328 A1. The process starts from a mass containing fibers, in which the mass appears as a homogenous mixture of fibers of different types. To this end, the mixture includes a synthetic fiber that melts at relatively low temperature and thereby effectuates adhesion and, moreover, a more heat-resistant fiber that absorbs harmful substances from tobacco smoke. The mixture is shaped into a cylindrical body, having dimensions of, e.g., a cigarette filter, before heat is applied. It is hereby achieved that the draw resistance is improved with increased filter effect. The process uses at least two different types of fibers, one of which is insensitive to the heat applied, but absorbs harmful substances in the smoke. The second fiber melts completely under the applied heat, through which the space originally occupied by this fiber forms a network of interconnected pores extending in all directions, which remains open for the smoke to pass through. The melted mass forms droplets at the intersections of the absorbing fibers, connecting them. [0004] The filters produced in this way have the disadvantage that an inhomogeneous distribution of the draw resistance is caused via the filter produced. Furthermore, the fibers absorbing the tobacco smoke or the components from the tobacco smoke are partially covered by the melted components so that the absorption properties are impaired. SUMMARY OF THE INVENTION [0005] In contrast, the present invention provides a filter that features a homogeneous structure, that can be produced simply and that can be very variably adjusted by the filter properties. Furthermore, the present invention provides a process with which the filter can be produced in a simple, effective and correspondingly variable and homogenous manner. [0006] The present invention is directed to a filter for articles of the tobacco processing industry, in particular for cigarettes, comprising at least two filter components. The filter is further developed in that one filter component is a sort of multiple-component fiber, in which a length of the multiple-component fibers is smaller than the length of the filter. [0007] Through the further development of the known filter according to the invention, this can be embodied in a very homogenous way, whereby a corresponding variability is rendered possible as well as a simple production. The length of the multiple-component fibers is preferably between 0.5 mm and 30 mm. Further, the length of the multiple-component fibers is also preferably between 2 mm and 8 mm and in particular between 3 mm and 6 mm. [0008] The multiple-component fibers include a core and a casing composed of different materials. According to the exemplary embodiment, the casing material features a lower melting point than the core material, such that a very secure bonding of the fibers in the filter can be produced, In this regard, the filter or the mixture of fibers from which the filter is made is brought to a temperature that is somewhat above the melting point of the casing material, so that a corresponding adhesion of filter components is rendered possible. The multiple-component fiber is preferably a bi-component fiber. With a corresponding bi-component fiber, the casing can be of polyethylene (PE) and the core, e.g., of polyester or polyethylene terephthalate (PET). The melting point of such a casing is then 127° C and the melting point of such a core is 256° C. In this way, a very dimensionally stable bi- component fiber is formed, in which the casing material has a lower melting point than its core material. A corresponding bi-component fiber is produced by Trevira (65926 Frankfurt, Germany). A bi-component fiber by Trevira preferably used by way of example has the type number 255, has a titer of 3.0 dtex, a cut length of between 3 and 6 mm, a core of PES (man-made fiber of polyester) and a shell or casing of copolyethylene, whereby the shell or casing is modified for increased adhesion, i.e., with additives provided to lead to a lower surface tension. (0009] In a preferred embodiment, at least a part of the filter components adhere and/or stick to the multiple-component fibers at contact points. Within the scope of this invention, the term "contact point" also includes the term "point of intersection" and "adhesion point." Adhesion and/or sticking is achieved when the filter components and, in particular, the multiple-component fibers are heated to a temperature above the casing melting temperature. In this regard, the casing correspondingly softens or begins to melt, so that at contact points of the multiple- component an adhesive connection or gluing connection to other components of the filter occurs at contact points. After the corresponding filter components have cooled, a dimensionally very stable filter is thus produced. [0010] In another exemplary embodiment, the filter also includes another filter component composed of other sorts of fibers. In this way, a very environmentally friendly filter can be produced when the other sorts of fibers are, e.g., biodegradable or can be produced biologically. In particular, cellulose fibers are preferably considered here or charcoal fibers, which can be activated. Other fibers, such as, e.g., hemp fibers or cotton fiber or the like, can also be utilized. These fibers preferably adsorb and/or absorb components of tobacco smoke effectively. Further, the length of the other sorts of fibers is preferably smaller than the length of the filter and is preferably between 0.1 mm and 30 mm and, in particular, between 0.2 mm and 10 mm. [0011] In a preferred embodiment of the invention, a powdery or granular material can be utilized as another filter component, such that it is possible very effectively filter gaseous smoke. The powdery or granular material is preferably activated charcoal powder or granulate of activated charcoal. Moreover, this material can be catalysts that increase the absorption of smoke components or generate or facilitate a chemical transformation (reaction) into components that are not hazardous to the smoker. A substantial advantage of the invention lies in that an effective surface of the powder or of the granulate, which forms another filter component, is clearly increased as compared with corresponding filters made of cellulose acetate mixed with powder, since no adhesive such as triacitin covers the surface. For example, adhesion only occurs to the multiple-component fibers, so that the part of the surface that does not adhere to the fiber remains free and thus is available for adsorption or absorption. In accordance with the invention, flavoring materials can be selected as the powdery or granular material. Thus, in accordance with the foregoing description, a smaller amount of the flavoring materials are necessary in order to achieve a same taste effect. Preferably, the powdery or granular material is an adsorbing material. [0012] In a preferred exemplary embodiment of the invention, a proportion of multiple-component fibers is between 2% and 100% and a proportion of other fibers is between 0% and 98%. Within the scope of the invention, the percentages of the proportions of materials are to be considered as percentages by weight (%wt). [0013] A filter that binds the cigarette smoke in a particularly effective manner is given when the filter includes a proportion of powdery or granular material that is between 80% by weight or 100 % by weight and preferably is 90% by weight. [0014] The filter is preferably a component of a multiple filter. Within the scope of this instant invention, the term "multiple filter" also includes the term "multi- segment filter." Thus, the filter according to the invention can be the entire filter or a segment of a multiple filter of, e.g., a cigarette. [0015] Further, the invention provides a process to manufacture a filter for articles of the tobacco processing industry. The process includes producing a rod, with at least one sort of multi-component fibers having lengths smaller than a length of the filter to be manufactured, heating the fiber rod to a temperature above a melting temperature of a casing of the at least one sort of multiple- component fibers, and cooling the fiber rod to a temperature below the melting temperature of the casing of the at least one sort of multiple-component fibers. [0016] Through the process according to the invention, it is possible to manufacture a very homogenous filter in a cost-effective manufacture, in which high variability is available. The temperature to which the fiber rod is heated is preferably greater than the melting temperature of the casing or the outer casing of the multiple-component fibers. With a casing of, e.g., polyethylene, this is over 127° C. If bi-component fibers are used, a core of polyester is preferred which has a melting temperature of 256°C, such that the fiber rod is heated to a temperature below 256° C, and is preferably heated in a temperature range between 127° C and 150° C. [0017] When, before the production of the rod, at least one other component is mixed into the at least one sort of multiple-component fibers, it is possible to manufacture a very cost-effective as well as environmentally friendly filter. By way of example, cellulose fiber is suitable as this other component, and can be purchased from, e.g., Stora Enso Pulp, in Falun, Sweden. In this regard, the cellulose fiber type under the name Stora Fluff EF can be utilized. Moreover, a powdery or granular component of an adsorber, absorber, catalyst or flavoring material can be used as the other component, either separately or in combination with each other and with the cellulose fiber. [0018] A particularly effective and simple process control is given when at least one part of the components is poured onto a conveyor to produce the rod. In this way, a corresponding filter rod or corresponding filter is manufactured in a particularly homogenous manner. Reference is hereby made to the manufacture of tobacco rods, which is described, e.g., in German Patent No. DE 36 24 098 C2, the disclosure of which is expressly incorporated by reference herein in its entirety. Preferably, the process can also be used for manufacturing filters, in such a manner that the initial components are first present in a loose mixture, i.e., before the manufacture of the rod, and then, as with tobacco rod manufacture, are poured on a suction belt and further processed. To this extent, the content of German Patent No. DE 36 24 098 C2 can thus be used for the manufacturing process of filters or filter rods. [0019J Preferably at least those components that are present in fiber form are poured. The poured fibers present in the mixture have a length that is preferably shorter than the length of the filter to be manufactured. Further, a particularly effective and cost-effective filter can then be manufactured when at least one other component in powder form or as granulate is added to the rod before heating or is added to the multiple-component fibers or the mixture during pouring. If, e.g., a powder of activated charcoal is added, it is possible to provide a very large surface on the charcoal powder particles, so that effectively fewer charcoal particles have to be added; Furthermore, in view of the instant invention, it is then no longer necessary to provide an active charcoal granulate filter for a multiple filter, which is relatively cost-intensive in the manufacture. Moreover, a more homogenous mixture of the powder in the multiple-component fibers or in the mixture of the fibers is possible than with a granulate filter. Still further, the draw resistance is more constant and can be better influenced. [0020] When the rod is shaped by a garniture apparatus, to produce, e.g., a cylindrical form, it is possible to manufacture the desired end measurements of the filter to be manufactured in a simple manner. In this connection, reference is once again made to German Patent Application No. DE 36 24 098 C2, in which a corresponding garniture apparatus is described for producing an endless rod. A garniture apparatus adapted to the physical properties of the filter components can be used according to this invention. Further, the rod is preferably compressed during shaping. Moreover, in accordance with an exemplary embodiment, it is possible to encase the rod within a suitable casing material, e.g., a paper strip, removed from a bobbin and laid on a driven garniture belt. The garniture belt then transports the filter rod or the combined fiber rod and paper strip through the garniture apparatus in order to fold the paper strip around the fiber rod. However, one edge of the paper strip projects from the rod, which is glued by a gluing device in a known manner. Finally the gluing seam is closed and dried by a seam sealer. [0021] The heating of the rod occurs in or after the shaping in the garniture apparatus. Preferably, the heating occurs after the cutting of the filter rod into filter nth use lengths or filter bars. Subsequently the filter, is cut to length or cut off. To this end, filters of nth use lengths are produced, which are subsequently used to produce, e,g,, filter cigarettes. In this regard, n is a natural number and preferably even. For example, when a filter is placed between, and subsequently connected to, two cut tobacco rods, n is two (2), such that this filter is of double use length and is to be cut through in the middle after connection with the cut tobacco rods, in order to serve as filter for two cigarettes. [0022] The invention is also directed to a filter manufactured according to the process of the instant invention or a preferred embodiment of the process according to the invention. Moreover, a cigarette is formed by a cut tobacco rod and a filters according to the invention. [0023] The present invention is directed to a filter for articles of the tobacco processing industry. The filter includes at least one filter component of multiple- component fibers. The multiple-component fibers have lengths shorter than a length of the filter. [0024] According to a feature of the invention, the filter can be manufactured for use with cigarettes. [0025] In accordance with another feature of the instant invention, the lengths of the multiple-component fibers can be between 0.5 mm and 30 mm. Further, the lengths of the multiple-component fibers can be between 2 mm and 8 mm, and, preferably, the lengths of the multiple-component fibers are between 3 mm and 6 mm. [0026] Further, the multiple-component fibers can include cores and casings composed of different materials. The casing material may have a lower melting point than the core material. [0027] According to still another feature of the instant invention, each of the multiple-component fibers may include a core and a casing composed of materials having different melting points. The casing material has a lower melting point than the core material. [0028] In accordance with a further feature of the invention, the multiple- component fibers can include bi-component fibers. [0029] The multiple-component fibers can be structured so that portions of the multiple-component fibers contacting each other adhere to each other forming contacting points. [0030] Moreover, the at least one filter component can further include other fibers, different from the multiple-component fibers. Lengths of the other fibers may be shorter than a length of the filter. The lengths of the other fibers are between 0.1 mm and 30 mm. Further, the lengths of the other fibers can be between 0.2 mm and 10 mm. Still further, the other fibers may include at least one of cellulose fibers and charcoal fibers. The at least one filter component may also include a powdery or granular material. The multiple-component fibers can be structured so that portions of the multiple-component fibers contacting each other and contacting portions of the other fibers adhere to each other forming contacting points. [0031] In accordance with another feature of the present invention, the filter can be composed of between 2 % wt. and 100 % wt. of the multiple-component fibers and between 0 % by wt. and 98 % by wt. of other fibers, which are different from the multiple-component fibers. Further, the other fibers may include at least one of cellulose fibers and charcoal fibers. The filter can also be composed of between 80 % wt. and 95 % wt. of a powdery or granular material. The powdery or granular material can include at least one of activated charcoal, an adsorber, an absorber, a catalyst and a flavoring material. Further, the multiple-component fibers are structured so that portions of the multiple-component fibers contacting each other, contacting portions of the other fibers, and contacting portions of the powdery or granular material adhere to each other forming contacting points. [0032] According to the present invention, the filter can be a component of a multiple filter. [0033] In accordance with another feature of the invention, a cigarette can include a filter as described above connected to a cigarette rod. [0034] The present invention is directed to a process for producing a filter for articles of the tobacco processing industry. The process includes producing a rod including at least one type of multiple-component fibers having lengths shorter than a length of the filter to be produced. Further, the multiple-component fibers have a casing. The process further includes heating the rod to a temperature above a melting temperature of the casing, and cooling the rod to a temperature below the melting temperature of the casing. [0035] In accordance with a feature of the invention, before producing the rod, the process can include mixing at least one other component, which is different from the multiple-component fibers, into the at least one type of multiple- component fibers. The producing of the rod may include pouring at least a part of the multiple-component fibers and the at least one other component onto a conveyor. Further, the at least one other component may include fibers. In particular, the at least one other component can include a powder or granulate. Further, the powder or granulate may be added to the rod prior to heating. Moreover, the powder of granulate can be added to the multiple-component fibers during pouring. The at least one other component may include other fibers, which are different-from the multiple-component fibers, and a powder or granulate. The powder can be added to a mixture of the multiple-component fibers and the other fibers during the pouring of the mixture onto the conveyor. [0036] According to another feature of the invention, the producing of the rod may include pouring at least a part of the multiple-component fibers onto a conveyor. [0037] According to the invention, the process can further include shaping the rod in a garniture apparatus, thereby producing a cylindrically shaped rod. Further, the heating of the rod can occur one of in or after the shaping in the garniture apparatus. [0038] In accordance with still another feature of the invention, the process can also include encasing the rod in a casing material. The casing material may include a casing paper. [0039] According to a further feature, the process can include cutting the filter to a desired length. [0040] Moreover, the process can include connecting cigarette rods to opposite ends of the filter, and cutting the filter in half to form two filtered cigarettes. [0041] According to the invention, a filtered cigarette is produced in accordance with the above-noted process. [0042] Still further, a filter may be produced in accordance with the above-noted process. [0043] Further still, a cigarette can include a filter produced in accordance with the above-noted process connected to a cigarette rod. [0044] The present invention is directed to a filter that includes multiple- component fibers having lengths shorter than a length of the filter. Portions of the multiple-component fibers are structured to adhere to each other to form contacting points. [0045] According to a feature of the invention, the multiple-component fibers comprising casings formed of a first material and cores formed of a second material different from the first material. The casings can have a lower melting point than the cores. Further, the connecting points may be formed by the cores melting together. Moreover, the first material may include at least one of polyester and polyethylene terephthalate and the second material can include polyethylene. [0046] In accordance with another feature of the invention, the filter can include an other component, different from the multiple-component fibers. Portions of the multiple-component fibers may be structured to adhere to the other component. Still further, the other component can include at least one of cellulose and charcoal fibers. Alternatively, or additionally, the other component may include a powdery or granulate material comprising at least one of activated charcoal, an adsorber, an absorber, a catalyst and a flavoring material. [0047] According to still another feature of the invention, the filter can be coupled to a cellulose acetate filter. [0048] In accordance with still yet another feature of the present invention, a cigarette includes a filter in accordance with the above-description and a cigarette rod. [0049] Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing. BRIEF DESCRIPTION OF THE DRAWINGS [0050] The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non- limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: [0051] Figures 1a - 1d diagrammatically illustrate cross-sections through filter cigarettes; [0052] Figure 2 illustrates a scanning electron microscope image of fibers adhered together in accordance with the invention; [0053] Figure 3 illustrates a scanning electron microscope image of a mixture of fibers in accordance with the invention; [0054] Figure 4 illustrates a scanning electron microscope image of a mixture of different fibers with an added powdery component; [0055] Figure 5 diagrammatically illustrates a cross-section through a filter cigarette produced in accordance with the instant invention; and [0056] Figure 6 illustrates a scanning electron microscope image of a mixture of a bi-component fiber and a charcoal activated granulate in accordance with the present invention. DETAILED DESCRIPTION OF THE PRESENT INVENTION [0057] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. [0058] Figures 1a - 1d diagrammatically illustrate cross-sections of filter cigarettes. Filters 10 in Figures 1a - 1d are each structured differently. Further, a cut tobacco rod 11 is attached to each filter, whereby cut tobacco rod 11 and filter 10, as shown in diagrammatic form, are provided with a casing paper 17. [0059] In Figure la, filter 10 comprises multiple-component fibers, i.e., bi- component fibers 12, e.g., bi-component fibers of type 255 by Trevira (65926 Frankfurt, Germany), which were described above with regard to their properties. Bi-component fibers 12 comprise a core 20 of, e.g., PES, a man-made fiber of polyester, or PET, i.e. polyethylene terephthalate. In this exemplary embodiment casing 21 is made of PE (polyethylene). The melting point of casing 21 is 127° C and the melting temperature of core 20 is 256°C. In order to produce the filter according to the invention, bi-component fibers 12 are correspondingly mixed, whereby loose fibers are used, which have a finite length shorter than the length of the filter to be produced. In this exemplary embodiment, bi-component fibers 12 have a cut length of 6 mm. The filter to be produced has a length of 21 mm. [0060] Bi-component fibers 12 are poured onto a suction conveyor for the production of the filter, in order to form a stream or a rod of bi-component fibers 12. This stream or rod of bi-component fibers 12 is then shaped into the filter shape, preferably cylindrical, by a garniture apparatus, and encased with a casing paper 17. In order to achieve a corresponding stability, the filter is brought to a temperature of above the melting temperature of casing 21 of bi-component fibers 12, so that casing 21 melts or begins to melt. After a subsequent cooling, connections have formed at intersection points 18 of bi-component fibers 12, which connections lead to a bonding of bi-component fibers 12 in the rod. The heating of the rod can occur before the shaping of the filter in the garniture apparatus. However, this heating can also occur during shaping or afterwards. A corresponding adhesion of bi-component fibers 12, as shown in Figure 2, occurs at a point of intersection 18 at which casing 21 material is accordingly melted. Through this connection it is possible to produce a very dimensionally stable filter. Moreover, it is noted that the length specification in the lower area of Figure 2 is 10 μm. [0061] Figure 1b shows a filter that is made of a mixture of fibers, including bi- component fibers 12 and cellulose fibers 13. In a preferred manner, a mixture of 20 to 30 % bi-component fibers 12 and 70 to 80 % cellulose fibers 13 is used. Cellulose fibers 13 hereby serve as absorption- or adsorption fibers and bi- component fibers 12, with the adhesion points at intersection points 18, serve as a framework. It should be noted that not only are bi-component fibers 12 adhered together, but also cellulose fibers 13 at intersection points 18 with bi-component fibers 12. [0062] In another exemplary, albeit unillustrated, embodiment, the filter is composed of 20% wt. bi-component fibers, 70% wt. cellulose fibers and 10 % wt. charcoal fibers, preferably, activated charcoal fibers. The advantage of such a filter with these three fiber components is that harmful gaseous substances are also well adsorbed from the smoke. A filter can be produced more cost-effectively than an activated charcoal granulate filter. Furthermore, a very homogenous filter can be realized. Finally, a higher activity is given, since the active fibers are not glued with a glue such as, triacetin, and, therefore, a larger active surface is rendered possible. Another scanning electron microscope image is shown in Figure 3, which illustrates a mixture of 20% wt. bi-component fibers 12 and 80 % wt. cellulose fibers 13. [0063] Figure 1c shows another filter that comprises three components, which includes an activated charcoal granulate 14 used as additional component These activated charcoal granulate particles or activated charcoal powder particles adhere or stick to the bi-component fibers at a corresponding adhesion point 19. Due to the small adhesion point or sticking point of charcoal particles 14 on bi- component fibers 12, a large free surface results with the charcoal particles, which surface is active. Other adsorbates, catalysts and/or flavoring materials can also be used instead of the activated charcoal particles or granulate, or powder. The grain size of the activated charcoal powder is normally a maximum of 10 um. For example, 20 mg can be added to a filter accordingly. [0064] Figure 4 shows a scanning electron microscope image of a corresponding part of a filter with a mixture of bi-component fibers 12, cellulose fibers 13 and particles of an activated charcoal powder 14. It can be easily observed that activated charcoal particles 14 adhere to bi-component fibers 12. However, some activated charcoal particles 14 are also arranged on cellulose fiber 13, which adhere there, although less firmly than to bi-component fiber 12. [0065] A multiple filter 10' is shown in Figure 1d that comprises a filter element 16, which can comprise, e.g., a conventional cellulose acetate filter 15, and a filter element 16', which can, e.g., correspond to the filter element depicted in Figure 1c. [0066] Through the filter according to the invention and the manufacturing process of the filter according to invention, there is a possibility of selecting and mixing the components of the filters such that smoke components can be specifically filtered out. [0067] A filter produced according to the invention preferably has a length of 21 mm, a diameter of 7.8 mm, a weight of 110 mg, and a draw resistance of 55 mmWS. The filter comprises 75 % wt. cellulose fibers of the type stora Fluff EF with a fiber length of 0.4 mm and 25 % wt. bi-component fibers of the type 255 by Trevira with a cut length of 6 mm and a diameter of 25 um. With the filter according to the invention, tar values of 12 mg/cig. and nicotine values of 0.87 mg/cig. are achieved with a ventilation of 18 %. [0068] Figure 5 shows a diagrammatic illustration of a cross section through a filter cigarette according to Figures 1a through 1d. In comparison to the examples of Figures 1a - 1d, the filter according to the invention comprises two filter elements 16 and 16', whereby filter element 16' is a mixture of bi-component fibers 12 and activated charcoal granulate 14 or activated charcoal powder 14. Further, a particularly preferred mixture includes between 80 and 95 % wt. activated charcoal granulate or powder 14 and 5 to 20 % wt. bi-component fibers 12. A mixture ratio of approx. 90 % wt. activated charcoal granulate or powder 14 and approx. 10 % wt. bi-component fibers 12 is particularly preferred. As noted, the percentages are in particular percentages by weight. [0069] The activated charcoal granulate or powder is, e.g., the granulate Norit GCN 3060 by Norit Nederland B.V. For 90 % of the granulate the grain size is between 0.25 mm and 0.59 mm. [0070] Figure 6 illustrates a scanning electron microscope image of a section through a filter according to the invention comprising approx. 10 % wt. bi- component fibers 12 and approx. 90 % wt. activated charcoal granulate 14. This figure is depicted as a 205 x magnification. In the lower area of Figure 6, a scale is shown that shows in total 1 mm, whereby the units within this scale are 100 μm. [0071] Activated charcoal granulate 14 is, as can be seen in Figure 6, held in a matrix of bi-component fibers 12, whereby holding is rendered possible in particular by adhesion to bi-component fibers 12, after they have been brought to the melting of the shell during the manufacturing process of the filter, [0072] It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. List of Reference Numbers 10 Filter 10' Multiple filter 11 Cut tobacco rod 12 Bi-component fiber 13 Cellulose fiber 14 Activated charcoal granulate 15 Cellulose acetate filter element 16 Filter element 16' Filter element 17 Casing paper 18 Point of intersection 19 Adhesion point 20 Core 21 Casing WE CLAIM 1. A filter (10,10') for any kind of item that is made of tobacco suitable for smoking by human beings, wherein said filter is manufactured for use with cigarettes, wherein the filter comprises: - at least one filter (10,10') component comprising multi-component fibers (12) characterized in that said multi-component fibers (12) having lengths shorter than a length of said filter (10,10'), in that said multi-component fibers (12,13,14) comprise cores (20) and casings (21) composed of different materials, and in that said casing material has a lower melting point than said core material 2. The filter as claimed in claim 1, wherein said lengths of said multi- component fibers (12,13,14) are between 0.5mm and 30mm. 3. The filter as claimed in claim 2, wherein said lengths of said multi- component fibers (12,13,14) are between 2mm and 8mm. 4. The filter as claimed in claim 2, wherein said lengths of said multi- component fibers (12,13,14) are between 3mm and 6mm. 5. The filter as claimed in claim 1, wherein each said multi-component fibers (12,13,14) comprises a core (20) and a casing (21) composed of materials having different melting points. 6. The filter as claimed in claim 5, wherein said casing (21) material has a lower melting point than said core (20) material. 7. The filter as claimed in claim 1, wherein said multi-component fibers comprise bi-component fibers (12). 8. The filter as claimed in claim 1, wherein said multi-component fibers (12,13,14) are structured so that portions of said multi-component fibers (12,13,14) containing each other adhere to each other forming contacting points (18,19). 9. The filter as claimed in claim 1, wherein said at least one filter component (10,10') further comprises other fibers (12), different from said multi- component fibers (12,13,14). 10.The filter as claimed in claim 9, wherein the lengths of said other fibers (12) are shorter than a length of said filter (10,10'). 11.The filter as claimed in claim 10, wherein said lengths of said other fibers (12) are between 0.1mm and 30mm. 12.The filter as claimed in claim 10, wherein said lengths of said other fibers (12) are between 0.2 and 10mm. 13.The filter as claimed in claim 9, wherein said other fibers (12) comprise at least one of cellulose fibers (15) and charcoal fibers (14). 14. The filter as claimed in claim 13, wherein said at least one filter component further comprises a powdery or granular material. 15. The filter as claimed in claim 9, wherein said multi-component fibers (12,13,14) are structured so that portions of said multi-component fibers (12,13,14) contacting each other and contacting portions of said other fibers adhere to each other forming contacting points (18,19). 16. The filter as claimed in claim 1, wherein said filter is composed of between 2% by wt. and 100% by wt. of said multi-component fibers and between 0% by wt. and 98% by wt. of other fibers, which are different from said multi-component fibers. 17. The filter as claimed in claim 16, wherein said other fibers comprise at least one of cellulose fibers (15) and charcoal fibers (14). 18. The filter as claimed in claim 16, wherein said filter is further composed of between 80% by wt. and 95% by wt. of a powdery or granular material. 19. The filter as claimed in claim 18, wherein said powdery or granular material comprises at least one of activated charcoal (14), an adsorber, a catalyst and a flavoring material. 20. The filter as claimed in claim 16, wherein said multi-component fibers (12,13,14) are structured so that portions of said multi-component fibers contacting each other, contacting portions of said other fibers, and contacting portions of said powdery or granular material adhere to each other forming contacting points (18,19). 21. The filter as claimed in claim 1, wherein said filter (10,10') is a component of a multiple filter (10'). 22. A cigarette comprising a filter as claimed in claim 1, connected to a cigarette rod. 23. A process for producing a filter (10,100 for any kind of item that is made of tobacco suitable for smoking by human beings: - producing a rod (11) comprising at least one type of multi-component fibers (12,13,14) having lengths shorter than a length of the filter (10,10') to be produced, the multi-component fiber having a casing (21) and a core (20),wherein the melting temperature of the core (20),wherein the melting temperature of the core (20) is above the melting temperature of the casing (21); - heating the rod (11) to a temperature above a melting temperature of the casing (21); and - cooling the rod (11) to a temperature below the melting temperature of the casing (21), wherein before producing the rod, the process comprises mixing at least one other component, which is different from the multi- component fibers, into the at least one type of multi-component fibers. 24. The process as claimed in claim 23, wherein the producing of the rod comprises pouring at least a part of the multi-component fibers and the at least one other component onto a conveyor. 25. The process as claimed in claim 24, wherein the at least one other component comprises fibers. 26. The process as claimed in claim 24, wherein the at least one other component comprises a powder or granulate. 27. The process as claimed in claim 26, wherein the powder of granulate is added to the rod prior to heating. 28. The process as claimed in claim 26, wherein the powder or granulate is added to the multi-component fibers during pouring. 29. The process as claimed in claim 24, wherein the at least one other component comprises other fibers which are different from the multi- component fiber, and a powder or granulate. 30. The process as claimed in claim 29, wherein the powder is added to a mixture of the multi-component fibers and the other fibers during the pouring of the mixture onto the conveyor. 31. The process as claimed in claim 23, wherein the producing of the rod comprises pouring at least a part of the multi-component fibers onto a conveyor. 32. The process as claimed in claim 23, further comprising shaping the rod in a garniture apparatus, thereby producing a cylindrically shaped rod. 33. The process as claimed in claim 32, wherein the heating of the rod occurs one of in or after the shaping in the garniture apparatus. 34. The process as claimed in claim 23, further comprising encasing the rod in a casing material. 35. The process as claimed in claim 34, wherein the casing (21) material comprises a casing paper (17). 36. The process as claimed in claim 23, further comprising cutting the filter to a desired length. 37. The process as claimed in claim 23, further comprising: - connecting cigarette rods to opposite ends of the filter; and - cutting the filter in half to form two filtered cigarettes. 38. A filter produced as claimed in claim 1 with the process of claim 23. 39. A filter comprising: - multi-components fibers having lengths shorter than a length of said filter; - portions of said multi-component fibers being structured to adhere to each other to form contacting points. 40.The filter as claimed in claim 39, wherein said multi-component fibers comprising casings formed of a first material and cores formed of a second material different from said first material. 41.The filter claimed in claim 40, wherein said casings having a lower melting point than said cores. 42.The filter claimed in claim 41, wherein said connecting points are formed by the casings or cores melting together. 43.The filter claimed in claim 40, wherein said first material comprises at least one of polyester and polyethylene terephthalate and said second material comprises polyethylene. 44.The filter claimed in claim 39 further comprises another component, different from said multi-component fibers, wherein portions of said multi- component fibers are structured to adhere to said other component. 45.The filter claimed in claim 44,wherein said other component comprises at least one of cellulose and charcoal fibers. 46.The filter claimed in claim 44, wherein said other component comprises a powder or granulate material comprising at least one of activated charcoal, an adsorber, a catalyst and a flavoring material. 47.The filter claimed in claim 46,wherein said other component further comprises at least one of cellulose and charcoal fibers. 48.The filter claimed in claim 39 being coupled to a cellulose acetate filter. 49.A cigarette comprising a filter claimed in claim 39 and a cigarette rod. Filter and process for producing filter (10,10') for articles of the tobacco processing industry. The filter includes at least one filter component of multiple- component fibers (12). The multiple-component fibers (12) have lengths shorter than a length of the filter (10,10'). The process includes producing a rod including at least one type of multi-component fibers (12) having lengths shorter than a length of the filter to be produced. Further, the multi-component fibers (12) have a casing (21). The process further includes heating the rod to a temperature above a melting temperature of the casing (21), and cooling the rod to a temperature below the melting temperature of the casing (21). The instant abstract is neither intended to define the invention disclosed in this specification nor attended to limited scope of the invention in any way.

Full Text

CIGARETTE FILTER AND PROCESS FOR MANUFACTURING THE
SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 of German
Patent Application No. 102 17 410.5, filed on April 18, 2002, the disclosure of
which is expressly incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a filter for articles of the tobacco
processing industry, e.g., for cigarettes, that includes at least two filter
components, in which one filter component is a sort of multiple-component fiber.
The invention further relates to a process for producing a corresponding filter for
articles of the tobacco processing industry, in particular for cigarettes.
2. Discussion of Background Information
[0003] A process for producing a filter mass, e.g., for cigarette filters, is known
from German Patent Application No. DE 30 28 328 A1. The process starts from a
mass containing fibers, in which the mass appears as a homogenous mixture of
fibers of different types. To this end, the mixture includes a synthetic fiber that
melts at relatively low temperature and thereby effectuates adhesion and,
moreover, a more heat-resistant fiber that absorbs harmful substances from
tobacco smoke. The mixture is shaped into a cylindrical body, having dimensions
of, e.g., a cigarette filter, before heat is applied. It is hereby achieved that the draw
resistance is improved with increased filter effect. The process uses at least two
different types of fibers, one of which is insensitive to the heat applied, but
absorbs harmful substances in the smoke. The second fiber melts completely
under the applied heat, through which the space originally occupied by this fiber
forms a network of interconnected pores extending in all directions, which remains
open for the smoke to pass through. The melted mass forms droplets at the
intersections of the absorbing fibers, connecting them.

[0004] The filters produced in this way have the disadvantage that an
inhomogeneous distribution of the draw resistance is caused via the filter
produced. Furthermore, the fibers absorbing the tobacco smoke or the
components from the tobacco smoke are partially covered by the melted
components so that the absorption properties are impaired.
SUMMARY OF THE INVENTION
[0005] In contrast, the present invention provides a filter that features a
homogeneous structure, that can be produced simply and that can be very variably
adjusted by the filter properties. Furthermore, the present invention provides a
process with which the filter can be produced in a simple, effective and
correspondingly variable and homogenous manner.
[0006] The present invention is directed to a filter for articles of the tobacco
processing industry, in particular for cigarettes, comprising at least two filter
components. The filter is further developed in that one filter component is a sort
of multiple-component fiber, in which a length of the multiple-component fibers is
smaller than the length of the filter.
[0007] Through the further development of the known filter according to the
invention, this can be embodied in a very homogenous way, whereby a
corresponding variability is rendered possible as well as a simple production. The
length of the multiple-component fibers is preferably between 0.5 mm and 30 mm.
Further, the length of the multiple-component fibers is also preferably between 2
mm and 8 mm and in particular between 3 mm and 6 mm.
[0008] The multiple-component fibers include a core and a casing composed of
different materials. According to the exemplary embodiment, the casing material
features a lower melting point than the core material, such that a very secure
bonding of the fibers in the filter can be produced, In this regard, the filter or the
mixture of fibers from which the filter is made is brought to a temperature that is
somewhat above the melting point of the casing material, so that a corresponding
adhesion of filter components is rendered possible. The multiple-component fiber

is preferably a bi-component fiber. With a corresponding bi-component fiber, the
casing can be of polyethylene (PE) and the core, e.g., of polyester or polyethylene
terephthalate (PET). The melting point of such a casing is then 127° C and the
melting point of such a core is 256° C. In this way, a very dimensionally stable bi-
component fiber is formed, in which the casing material has a lower melting point
than its core material. A corresponding bi-component fiber is produced by Trevira
(65926 Frankfurt, Germany). A bi-component fiber by Trevira preferably used by
way of example has the type number 255, has a titer of 3.0 dtex, a cut length of
between 3 and 6 mm, a core of PES (man-made fiber of polyester) and a shell or
casing of copolyethylene, whereby the shell or casing is modified for increased
adhesion, i.e., with additives provided to lead to a lower surface tension.
(0009] In a preferred embodiment, at least a part of the filter components adhere
and/or stick to the multiple-component fibers at contact points. Within the scope
of this invention, the term "contact point" also includes the term "point of
intersection" and "adhesion point." Adhesion and/or sticking is achieved when the
filter components and, in particular, the multiple-component fibers are heated to a
temperature above the casing melting temperature. In this regard, the casing
correspondingly softens or begins to melt, so that at contact points of the multiple-
component an adhesive connection or gluing connection to other components of
the filter occurs at contact points. After the corresponding filter components have
cooled, a dimensionally very stable filter is thus produced.
[0010] In another exemplary embodiment, the filter also includes another filter
component composed of other sorts of fibers. In this way, a very environmentally
friendly filter can be produced when the other sorts of fibers are, e.g.,
biodegradable or can be produced biologically. In particular, cellulose fibers are
preferably considered here or charcoal fibers, which can be activated. Other
fibers, such as, e.g., hemp fibers or cotton fiber or the like, can also be utilized.
These fibers preferably adsorb and/or absorb components of tobacco smoke
effectively. Further, the length of the other sorts of fibers is preferably smaller

than the length of the filter and is preferably between 0.1 mm and 30 mm and, in
particular, between 0.2 mm and 10 mm.
[0011] In a preferred embodiment of the invention, a powdery or granular
material can be utilized as another filter component, such that it is possible very
effectively filter gaseous smoke. The powdery or granular material is preferably
activated charcoal powder or granulate of activated charcoal. Moreover, this
material can be catalysts that increase the absorption of smoke components or
generate or facilitate a chemical transformation (reaction) into components that are
not hazardous to the smoker. A substantial advantage of the invention lies in that
an effective surface of the powder or of the granulate, which forms another filter
component, is clearly increased as compared with corresponding filters made of
cellulose acetate mixed with powder, since no adhesive such as triacitin covers the
surface. For example, adhesion only occurs to the multiple-component fibers, so
that the part of the surface that does not adhere to the fiber remains free and thus is
available for adsorption or absorption. In accordance with the invention, flavoring
materials can be selected as the powdery or granular material. Thus, in
accordance with the foregoing description, a smaller amount of the flavoring
materials are necessary in order to achieve a same taste effect. Preferably, the
powdery or granular material is an adsorbing material.
[0012] In a preferred exemplary embodiment of the invention, a proportion of
multiple-component fibers is between 2% and 100% and a proportion of other
fibers is between 0% and 98%. Within the scope of the invention, the percentages
of the proportions of materials are to be considered as percentages by weight
(%wt).
[0013] A filter that binds the cigarette smoke in a particularly effective manner
is given when the filter includes a proportion of powdery or granular material that
is between 80% by weight or 100 % by weight and preferably is 90% by weight.
[0014] The filter is preferably a component of a multiple filter. Within the scope
of this instant invention, the term "multiple filter" also includes the term "multi-

segment filter." Thus, the filter according to the invention can be the entire filter
or a segment of a multiple filter of, e.g., a cigarette.
[0015] Further, the invention provides a process to manufacture a filter for
articles of the tobacco processing industry. The process includes producing a rod,
with at least one sort of multi-component fibers having lengths smaller than a
length of the filter to be manufactured, heating the fiber rod to a temperature
above a melting temperature of a casing of the at least one sort of multiple-
component fibers, and cooling the fiber rod to a temperature below the melting
temperature of the casing of the at least one sort of multiple-component fibers.
[0016] Through the process according to the invention, it is possible to
manufacture a very homogenous filter in a cost-effective manufacture, in which
high variability is available. The temperature to which the fiber rod is heated is
preferably greater than the melting temperature of the casing or the outer casing of
the multiple-component fibers. With a casing of, e.g., polyethylene, this is over
127° C. If bi-component fibers are used, a core of polyester is preferred which has
a melting temperature of 256°C, such that the fiber rod is heated to a temperature
below 256° C, and is preferably heated in a temperature range between 127° C and
150° C.
[0017] When, before the production of the rod, at least one other component is
mixed into the at least one sort of multiple-component fibers, it is possible to
manufacture a very cost-effective as well as environmentally friendly filter. By
way of example, cellulose fiber is suitable as this other component, and can be
purchased from, e.g., Stora Enso Pulp, in Falun, Sweden. In this regard, the
cellulose fiber type under the name Stora Fluff EF can be utilized. Moreover, a
powdery or granular component of an adsorber, absorber, catalyst or flavoring
material can be used as the other component, either separately or in combination
with each other and with the cellulose fiber.
[0018] A particularly effective and simple process control is given when at least
one part of the components is poured onto a conveyor to produce the rod. In this

way, a corresponding filter rod or corresponding filter is manufactured in a
particularly homogenous manner. Reference is hereby made to the manufacture of
tobacco rods, which is described, e.g., in German Patent No. DE 36 24 098 C2, the
disclosure of which is expressly incorporated by reference herein in its entirety.
Preferably, the process can also be used for manufacturing filters, in such a
manner that the initial components are first present in a loose mixture, i.e., before
the manufacture of the rod, and then, as with tobacco rod manufacture, are poured
on a suction belt and further processed. To this extent, the content of German
Patent No. DE 36 24 098 C2 can thus be used for the manufacturing process of
filters or filter rods.
[0019J Preferably at least those components that are present in fiber form are
poured. The poured fibers present in the mixture have a length that is preferably
shorter than the length of the filter to be manufactured. Further, a particularly
effective and cost-effective filter can then be manufactured when at least one other
component in powder form or as granulate is added to the rod before heating or is
added to the multiple-component fibers or the mixture during pouring. If, e.g., a
powder of activated charcoal is added, it is possible to provide a very large surface
on the charcoal powder particles, so that effectively fewer charcoal particles have
to be added; Furthermore, in view of the instant invention, it is then no longer
necessary to provide an active charcoal granulate filter for a multiple filter, which
is relatively cost-intensive in the manufacture. Moreover, a more homogenous
mixture of the powder in the multiple-component fibers or in the mixture of the
fibers is possible than with a granulate filter. Still further, the draw resistance is
more constant and can be better influenced.
[0020] When the rod is shaped by a garniture apparatus, to produce, e.g., a
cylindrical form, it is possible to manufacture the desired end measurements of the
filter to be manufactured in a simple manner. In this connection, reference is once
again made to German Patent Application No. DE 36 24 098 C2, in which a
corresponding garniture apparatus is described for producing an endless rod. A

garniture apparatus adapted to the physical properties of the filter components can
be used according to this invention. Further, the rod is preferably compressed
during shaping. Moreover, in accordance with an exemplary embodiment, it is
possible to encase the rod within a suitable casing material, e.g., a paper strip,
removed from a bobbin and laid on a driven garniture belt. The garniture belt then
transports the filter rod or the combined fiber rod and paper strip through the
garniture apparatus in order to fold the paper strip around the fiber rod. However,
one edge of the paper strip projects from the rod, which is glued by a gluing
device in a known manner. Finally the gluing seam is closed and dried by a seam
sealer.
[0021] The heating of the rod occurs in or after the shaping in the garniture
apparatus. Preferably, the heating occurs after the cutting of the filter rod into
filter nth use lengths or filter bars. Subsequently the filter, is cut to length or cut
off. To this end, filters of nth use lengths are produced, which are subsequently
used to produce, e,g,, filter cigarettes. In this regard, n is a natural number and
preferably even. For example, when a filter is placed between, and subsequently
connected to, two cut tobacco rods, n is two (2), such that this filter is of double
use length and is to be cut through in the middle after connection with the cut
tobacco rods, in order to serve as filter for two cigarettes.
[0022] The invention is also directed to a filter manufactured according to the
process of the instant invention or a preferred embodiment of the process
according to the invention. Moreover, a cigarette is formed by a cut tobacco rod
and a filters according to the invention.
[0023] The present invention is directed to a filter for articles of the tobacco
processing industry. The filter includes at least one filter component of multiple-
component fibers. The multiple-component fibers have lengths shorter than a
length of the filter.
[0024] According to a feature of the invention, the filter can be manufactured for
use with cigarettes.

[0025] In accordance with another feature of the instant invention, the lengths of
the multiple-component fibers can be between 0.5 mm and 30 mm. Further, the
lengths of the multiple-component fibers can be between 2 mm and 8 mm, and,
preferably, the lengths of the multiple-component fibers are between 3 mm and 6
mm.
[0026] Further, the multiple-component fibers can include cores and casings
composed of different materials. The casing material may have a lower melting
point than the core material.
[0027] According to still another feature of the instant invention, each of the
multiple-component fibers may include a core and a casing composed of materials
having different melting points. The casing material has a lower melting point
than the core material.
[0028] In accordance with a further feature of the invention, the multiple-
component fibers can include bi-component fibers.
[0029] The multiple-component fibers can be structured so that portions of the
multiple-component fibers contacting each other adhere to each other forming
contacting points.
[0030] Moreover, the at least one filter component can further include other
fibers, different from the multiple-component fibers. Lengths of the other fibers
may be shorter than a length of the filter. The lengths of the other fibers are
between 0.1 mm and 30 mm. Further, the lengths of the other fibers can be
between 0.2 mm and 10 mm. Still further, the other fibers may include at least
one of cellulose fibers and charcoal fibers. The at least one filter component may
also include a powdery or granular material. The multiple-component fibers can
be structured so that portions of the multiple-component fibers contacting each
other and contacting portions of the other fibers adhere to each other forming
contacting points.
[0031] In accordance with another feature of the present invention, the filter can
be composed of between 2 % wt. and 100 % wt. of the multiple-component fibers

and between 0 % by wt. and 98 % by wt. of other fibers, which are different from
the multiple-component fibers. Further, the other fibers may include at least one
of cellulose fibers and charcoal fibers. The filter can also be composed of between
80 % wt. and 95 % wt. of a powdery or granular material. The powdery or
granular material can include at least one of activated charcoal, an adsorber, an
absorber, a catalyst and a flavoring material. Further, the multiple-component
fibers are structured so that portions of the multiple-component fibers contacting
each other, contacting portions of the other fibers, and contacting portions of the
powdery or granular material adhere to each other forming contacting points.
[0032] According to the present invention, the filter can be a component of a
multiple filter.
[0033] In accordance with another feature of the invention, a cigarette can
include a filter as described above connected to a cigarette rod.
[0034] The present invention is directed to a process for producing a filter for
articles of the tobacco processing industry. The process includes producing a rod
including at least one type of multiple-component fibers having lengths shorter
than a length of the filter to be produced. Further, the multiple-component fibers
have a casing. The process further includes heating the rod to a temperature above
a melting temperature of the casing, and cooling the rod to a temperature below
the melting temperature of the casing.
[0035] In accordance with a feature of the invention, before producing the rod,
the process can include mixing at least one other component, which is different
from the multiple-component fibers, into the at least one type of multiple-
component fibers. The producing of the rod may include pouring at least a part of
the multiple-component fibers and the at least one other component onto a
conveyor. Further, the at least one other component may include fibers. In
particular, the at least one other component can include a powder or granulate.
Further, the powder or granulate may be added to the rod prior to heating.
Moreover, the powder of granulate can be added to the multiple-component fibers

during pouring. The at least one other component may include other fibers, which
are different-from the multiple-component fibers, and a powder or granulate. The
powder can be added to a mixture of the multiple-component fibers and the other
fibers during the pouring of the mixture onto the conveyor.
[0036] According to another feature of the invention, the producing of the rod
may include pouring at least a part of the multiple-component fibers onto a
conveyor.
[0037] According to the invention, the process can further include shaping the
rod in a garniture apparatus, thereby producing a cylindrically shaped rod.
Further, the heating of the rod can occur one of in or after the shaping in the
garniture apparatus.
[0038] In accordance with still another feature of the invention, the process can
also include encasing the rod in a casing material. The casing material may
include a casing paper.
[0039] According to a further feature, the process can include cutting the filter to
a desired length.
[0040] Moreover, the process can include connecting cigarette rods to opposite
ends of the filter, and cutting the filter in half to form two filtered cigarettes.
[0041] According to the invention, a filtered cigarette is produced in accordance
with the above-noted process.
[0042] Still further, a filter may be produced in accordance with the above-noted
process.
[0043] Further still, a cigarette can include a filter produced in accordance with
the above-noted process connected to a cigarette rod.
[0044] The present invention is directed to a filter that includes multiple-
component fibers having lengths shorter than a length of the filter. Portions of the
multiple-component fibers are structured to adhere to each other to form
contacting points.

[0045] According to a feature of the invention, the multiple-component fibers
comprising casings formed of a first material and cores formed of a second
material different from the first material. The casings can have a lower melting
point than the cores. Further, the connecting points may be formed by the cores
melting together. Moreover, the first material may include at least one of
polyester and polyethylene terephthalate and the second material can include
polyethylene.
[0046] In accordance with another feature of the invention, the filter can include
an other component, different from the multiple-component fibers. Portions of the
multiple-component fibers may be structured to adhere to the other component.
Still further, the other component can include at least one of cellulose and charcoal
fibers. Alternatively, or additionally, the other component may include a powdery
or granulate material comprising at least one of activated charcoal, an adsorber, an
absorber, a catalyst and a flavoring material.
[0047] According to still another feature of the invention, the filter can be
coupled to a cellulose acetate filter.
[0048] In accordance with still yet another feature of the present invention, a
cigarette includes a filter in accordance with the above-description and a cigarette
rod.
[0049] Other exemplary embodiments and advantages of the present invention
may be ascertained by reviewing the present disclosure and the accompanying
drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The present invention is further described in the detailed description
which follows, in reference to the noted plurality of drawings by way of non-
limiting examples of exemplary embodiments of the present invention, in which
like reference numerals represent similar parts throughout the several views of the
drawings, and wherein:

[0051] Figures 1a - 1d diagrammatically illustrate cross-sections through filter
cigarettes;
[0052] Figure 2 illustrates a scanning electron microscope image of fibers
adhered together in accordance with the invention;
[0053] Figure 3 illustrates a scanning electron microscope image of a mixture of
fibers in accordance with the invention;
[0054] Figure 4 illustrates a scanning electron microscope image of a mixture of
different fibers with an added powdery component;
[0055] Figure 5 diagrammatically illustrates a cross-section through a filter
cigarette produced in accordance with the instant invention; and
[0056] Figure 6 illustrates a scanning electron microscope image of a mixture of
a bi-component fiber and a charcoal activated granulate in accordance with the
present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0057] The particulars shown herein are by way of example and for purposes of
illustrative discussion of the embodiments of the present invention only and are
presented in the cause of providing what is believed to be the most useful and
readily understood description of the principles and conceptual aspects of the
present invention. In this regard, no attempt is made to show structural details of
the present invention in more detail than is necessary for the fundamental
understanding of the present invention, the description taken with the drawings
making apparent to those skilled in the art how the several forms of the present
invention may be embodied in practice.
[0058] Figures 1a - 1d diagrammatically illustrate cross-sections of filter
cigarettes. Filters 10 in Figures 1a - 1d are each structured differently. Further, a
cut tobacco rod 11 is attached to each filter, whereby cut tobacco rod 11 and filter
10, as shown in diagrammatic form, are provided with a casing paper 17.
[0059] In Figure la, filter 10 comprises multiple-component fibers, i.e., bi-
component fibers 12, e.g., bi-component fibers of type 255 by Trevira (65926

Frankfurt, Germany), which were described above with regard to their properties.
Bi-component fibers 12 comprise a core 20 of, e.g., PES, a man-made fiber of
polyester, or PET, i.e. polyethylene terephthalate. In this exemplary embodiment
casing 21 is made of PE (polyethylene). The melting point of casing 21 is 127° C
and the melting temperature of core 20 is 256°C. In order to produce the filter
according to the invention, bi-component fibers 12 are correspondingly mixed,
whereby loose fibers are used, which have a finite length shorter than the length of
the filter to be produced. In this exemplary embodiment, bi-component fibers 12
have a cut length of 6 mm. The filter to be produced has a length of 21 mm.
[0060] Bi-component fibers 12 are poured onto a suction conveyor for the
production of the filter, in order to form a stream or a rod of bi-component fibers
12. This stream or rod of bi-component fibers 12 is then shaped into the filter
shape, preferably cylindrical, by a garniture apparatus, and encased with a casing
paper 17. In order to achieve a corresponding stability, the filter is brought to a
temperature of above the melting temperature of casing 21 of bi-component fibers
12, so that casing 21 melts or begins to melt. After a subsequent cooling,
connections have formed at intersection points 18 of bi-component fibers 12,
which connections lead to a bonding of bi-component fibers 12 in the rod. The
heating of the rod can occur before the shaping of the filter in the garniture
apparatus. However, this heating can also occur during shaping or afterwards. A
corresponding adhesion of bi-component fibers 12, as shown in Figure 2, occurs at
a point of intersection 18 at which casing 21 material is accordingly melted.
Through this connection it is possible to produce a very dimensionally stable
filter. Moreover, it is noted that the length specification in the lower area of
Figure 2 is 10 μm.
[0061] Figure 1b shows a filter that is made of a mixture of fibers, including bi-
component fibers 12 and cellulose fibers 13. In a preferred manner, a mixture of
20 to 30 % bi-component fibers 12 and 70 to 80 % cellulose fibers 13 is used.
Cellulose fibers 13 hereby serve as absorption- or adsorption fibers and bi-

component fibers 12, with the adhesion points at intersection points 18, serve as a
framework. It should be noted that not only are bi-component fibers 12 adhered
together, but also cellulose fibers 13 at intersection points 18 with bi-component
fibers 12.
[0062] In another exemplary, albeit unillustrated, embodiment, the filter is
composed of 20% wt. bi-component fibers, 70% wt. cellulose fibers and 10 % wt.
charcoal fibers, preferably, activated charcoal fibers. The advantage of such a
filter with these three fiber components is that harmful gaseous substances are also
well adsorbed from the smoke. A filter can be produced more cost-effectively
than an activated charcoal granulate filter. Furthermore, a very homogenous filter
can be realized. Finally, a higher activity is given, since the active fibers are not
glued with a glue such as, triacetin, and, therefore, a larger active surface is
rendered possible. Another scanning electron microscope image is shown in
Figure 3, which illustrates a mixture of 20% wt. bi-component fibers 12 and 80 %
wt. cellulose fibers 13.
[0063] Figure 1c shows another filter that comprises three components, which
includes an activated charcoal granulate 14 used as additional component These
activated charcoal granulate particles or activated charcoal powder particles
adhere or stick to the bi-component fibers at a corresponding adhesion point 19.
Due to the small adhesion point or sticking point of charcoal particles 14 on bi-
component fibers 12, a large free surface results with the charcoal particles, which
surface is active. Other adsorbates, catalysts and/or flavoring materials can also be
used instead of the activated charcoal particles or granulate, or powder. The grain
size of the activated charcoal powder is normally a maximum of 10 um. For
example, 20 mg can be added to a filter accordingly.
[0064] Figure 4 shows a scanning electron microscope image of a corresponding
part of a filter with a mixture of bi-component fibers 12, cellulose fibers 13 and
particles of an activated charcoal powder 14. It can be easily observed that
activated charcoal particles 14 adhere to bi-component fibers 12. However, some

activated charcoal particles 14 are also arranged on cellulose fiber 13, which
adhere there, although less firmly than to bi-component fiber 12.
[0065] A multiple filter 10' is shown in Figure 1d that comprises a filter element
16, which can comprise, e.g., a conventional cellulose acetate filter 15, and a filter
element 16', which can, e.g., correspond to the filter element depicted in Figure
1c.
[0066] Through the filter according to the invention and the manufacturing
process of the filter according to invention, there is a possibility of selecting and
mixing the components of the filters such that smoke components can be
specifically filtered out.
[0067] A filter produced according to the invention preferably has a length of 21
mm, a diameter of 7.8 mm, a weight of 110 mg, and a draw resistance of 55
mmWS. The filter comprises 75 % wt. cellulose fibers of the type stora Fluff EF
with a fiber length of 0.4 mm and 25 % wt. bi-component fibers of the type 255 by
Trevira with a cut length of 6 mm and a diameter of 25 um. With the filter
according to the invention, tar values of 12 mg/cig. and nicotine values of 0.87
mg/cig. are achieved with a ventilation of 18 %.
[0068] Figure 5 shows a diagrammatic illustration of a cross section through a
filter cigarette according to Figures 1a through 1d. In comparison to the examples
of Figures 1a - 1d, the filter according to the invention comprises two filter
elements 16 and 16', whereby filter element 16' is a mixture of bi-component
fibers 12 and activated charcoal granulate 14 or activated charcoal powder 14.
Further, a particularly preferred mixture includes between 80 and 95 % wt.
activated charcoal granulate or powder 14 and 5 to 20 % wt. bi-component fibers
12. A mixture ratio of approx. 90 % wt. activated charcoal granulate or powder 14
and approx. 10 % wt. bi-component fibers 12 is particularly preferred. As noted,
the percentages are in particular percentages by weight.

[0069] The activated charcoal granulate or powder is, e.g., the granulate Norit
GCN 3060 by Norit Nederland B.V. For 90 % of the granulate the grain size is
between 0.25 mm and 0.59 mm.
[0070] Figure 6 illustrates a scanning electron microscope image of a section
through a filter according to the invention comprising approx. 10 % wt. bi-
component fibers 12 and approx. 90 % wt. activated charcoal granulate 14. This
figure is depicted as a 205 x magnification. In the lower area of Figure 6, a scale
is shown that shows in total 1 mm, whereby the units within this scale are 100 μm.
[0071] Activated charcoal granulate 14 is, as can be seen in Figure 6, held in a
matrix of bi-component fibers 12, whereby holding is rendered possible in
particular by adhesion to bi-component fibers 12, after they have been brought to
the melting of the shell during the manufacturing process of the filter,
[0072] It is noted that the foregoing examples have been provided merely for the
purpose of explanation and are in no way to be construed as limiting of the present
invention. While the present invention has been described with reference to an
exemplary embodiment, it is understood that the words which have been used
herein are words of description and illustration, rather than words of limitation.
Changes may be made, within the purview of the appended claims, as presently
stated and as amended, without departing from the scope and spirit of the present
invention in its aspects. Although the present invention has been described herein
with reference to particular means, materials and embodiments, the present
invention is not intended to be limited to the particulars disclosed herein; rather,
the present invention extends to all functionally equivalent structures, methods and
uses, such as are within the scope of the appended claims.

List of Reference Numbers
10 Filter
10' Multiple filter
11 Cut tobacco rod
12 Bi-component fiber
13 Cellulose fiber
14 Activated charcoal granulate
15 Cellulose acetate filter element
16 Filter element
16' Filter element
17 Casing paper
18 Point of intersection
19 Adhesion point
20 Core
21 Casing

WE CLAIM
1. A filter (10,10') for any kind of item that is made of tobacco suitable for
smoking by human beings, wherein said filter is manufactured for use
with cigarettes, wherein the filter comprises:
- at least one filter (10,10') component comprising multi-component fibers
(12) characterized in that said multi-component fibers (12) having lengths
shorter than a length of said filter (10,10'), in that said multi-component
fibers (12,13,14) comprise cores (20) and casings (21) composed of
different materials, and in that said casing material has a lower melting
point than said core material
2. The filter as claimed in claim 1, wherein said lengths of said multi-
component fibers (12,13,14) are between 0.5mm and 30mm.
3. The filter as claimed in claim 2, wherein said lengths of said multi-
component fibers (12,13,14) are between 2mm and 8mm.
4. The filter as claimed in claim 2, wherein said lengths of said multi-
component fibers (12,13,14) are between 3mm and 6mm.
5. The filter as claimed in claim 1, wherein each said multi-component fibers
(12,13,14) comprises a core (20) and a casing (21) composed of materials
having different melting points.

6. The filter as claimed in claim 5, wherein said casing (21) material has a
lower melting point than said core (20) material.
7. The filter as claimed in claim 1, wherein said multi-component fibers
comprise bi-component fibers (12).
8. The filter as claimed in claim 1, wherein said multi-component fibers
(12,13,14) are structured so that portions of said multi-component fibers
(12,13,14) containing each other adhere to each other forming contacting
points (18,19).
9. The filter as claimed in claim 1, wherein said at least one filter component
(10,10') further comprises other fibers (12), different from said multi-
component fibers (12,13,14).
10.The filter as claimed in claim 9, wherein the lengths of said other fibers
(12) are shorter than a length of said filter (10,10').
11.The filter as claimed in claim 10, wherein said lengths of said other fibers
(12) are between 0.1mm and 30mm.
12.The filter as claimed in claim 10, wherein said lengths of said other fibers
(12) are between 0.2 and 10mm.
13.The filter as claimed in claim 9, wherein said other fibers (12) comprise at
least one of cellulose fibers (15) and charcoal fibers (14).

14. The filter as claimed in claim 13, wherein said at least one filter
component further comprises a powdery or granular material.
15. The filter as claimed in claim 9, wherein said multi-component fibers
(12,13,14) are structured so that portions of said multi-component fibers
(12,13,14) contacting each other and contacting portions of said other
fibers adhere to each other forming contacting points (18,19).
16. The filter as claimed in claim 1, wherein said filter is composed of between
2% by wt. and 100% by wt. of said multi-component fibers and between
0% by wt. and 98% by wt. of other fibers, which are different from said
multi-component fibers.
17. The filter as claimed in claim 16, wherein said other fibers comprise at
least one of cellulose fibers (15) and charcoal fibers (14).
18. The filter as claimed in claim 16, wherein said filter is further composed of
between 80% by wt. and 95% by wt. of a powdery or granular material.
19. The filter as claimed in claim 18, wherein said powdery or granular
material comprises at least one of activated charcoal (14), an adsorber, a
catalyst and a flavoring material.
20. The filter as claimed in claim 16, wherein said multi-component fibers
(12,13,14) are structured so that portions of said multi-component fibers
contacting each other, contacting portions of said other fibers, and

contacting portions of said powdery or granular material adhere to each
other forming contacting points (18,19).
21. The filter as claimed in claim 1, wherein said filter (10,10') is a component
of a multiple filter (10').
22. A cigarette comprising a filter as claimed in claim 1, connected to a
cigarette rod.
23. A process for producing a filter (10,100 for any kind of item that is made
of tobacco suitable for smoking by human beings:
- producing a rod (11) comprising at least one type of multi-component
fibers (12,13,14) having lengths shorter than a length of the filter (10,10')
to be produced, the multi-component fiber having a casing (21) and a
core (20),wherein the melting temperature of the core (20),wherein the
melting temperature of the core (20) is above the melting temperature of
the casing (21);
- heating the rod (11) to a temperature above a melting temperature of the
casing (21); and
- cooling the rod (11) to a temperature below the melting temperature of
the casing (21), wherein before producing the rod, the process comprises
mixing at least one other component, which is different from the multi-
component fibers, into the at least one type of multi-component fibers.

24. The process as claimed in claim 23, wherein the producing of the rod
comprises pouring at least a part of the multi-component fibers and the at
least one other component onto a conveyor.
25. The process as claimed in claim 24, wherein the at least one other
component comprises fibers.
26. The process as claimed in claim 24, wherein the at least one other
component comprises a powder or granulate.
27. The process as claimed in claim 26, wherein the powder of granulate is
added to the rod prior to heating.
28. The process as claimed in claim 26, wherein the powder or granulate is
added to the multi-component fibers during pouring.
29. The process as claimed in claim 24, wherein the at least one other
component comprises other fibers which are different from the multi-
component fiber, and a powder or granulate.
30. The process as claimed in claim 29, wherein the powder is added to a
mixture of the multi-component fibers and the other fibers during the
pouring of the mixture onto the conveyor.

31. The process as claimed in claim 23, wherein the producing of the rod
comprises pouring at least a part of the multi-component fibers onto a
conveyor.
32. The process as claimed in claim 23, further comprising shaping the rod in
a garniture apparatus, thereby producing a cylindrically shaped rod.
33. The process as claimed in claim 32, wherein the heating of the rod occurs
one of in or after the shaping in the garniture apparatus.
34. The process as claimed in claim 23, further comprising encasing the rod in
a casing material.
35. The process as claimed in claim 34, wherein the casing (21) material
comprises a casing paper (17).
36. The process as claimed in claim 23, further comprising cutting the filter to
a desired length.
37. The process as claimed in claim 23, further comprising:
- connecting cigarette rods to opposite ends of the filter; and
- cutting the filter in half to form two filtered cigarettes.

38. A filter produced as claimed in claim 1 with the process of claim 23.
39. A filter comprising:

- multi-components fibers having lengths shorter than a length of said filter;
- portions of said multi-component fibers being structured to adhere to each
other to form contacting points.
40.The filter as claimed in claim 39, wherein said multi-component fibers
comprising casings formed of a first material and cores formed of a
second material different from said first material.
41.The filter claimed in claim 40, wherein said casings having a lower melting
point than said cores.
42.The filter claimed in claim 41, wherein said connecting points are formed
by the casings or cores melting together.
43.The filter claimed in claim 40, wherein said first material comprises at
least one of polyester and polyethylene terephthalate and said second
material comprises polyethylene.
44.The filter claimed in claim 39 further comprises another component,
different from said multi-component fibers, wherein portions of said multi-
component fibers are structured to adhere to said other component.
45.The filter claimed in claim 44,wherein said other component comprises at
least one of cellulose and charcoal fibers.

46.The filter claimed in claim 44, wherein said other component comprises a
powder or granulate material comprising at least one of activated
charcoal, an adsorber, a catalyst and a flavoring material.
47.The filter claimed in claim 46,wherein said other component further
comprises at least one of cellulose and charcoal fibers.
48.The filter claimed in claim 39 being coupled to a cellulose acetate filter.
49.A cigarette comprising a filter claimed in claim 39 and a cigarette rod.

Filter and process for producing filter (10,10') for articles of the tobacco
processing industry. The filter includes at least one filter component of multiple-
component fibers (12). The multiple-component fibers (12) have lengths shorter
than a length of the filter (10,10'). The process includes producing a rod
including at least one type of multi-component fibers (12) having lengths shorter
than a length of the filter to be produced. Further, the multi-component fibers
(12) have a casing (21). The process further includes heating the rod to a
temperature above a melting temperature of the casing (21), and cooling the rod
to a temperature below the melting temperature of the casing (21). The instant
abstract is neither intended to define the invention disclosed in this specification
nor attended to limited scope of the invention in any way.

Documents:

213-kol-2003-granted-abstract.pdf

213-kol-2003-granted-claims.pdf

213-kol-2003-granted-correspondence.pdf

213-kol-2003-granted-description (complete).pdf

213-kol-2003-granted-drawings.pdf

213-kol-2003-granted-examination report.pdf

213-kol-2003-granted-form 1.pdf

213-kol-2003-granted-form 18.pdf

213-kol-2003-granted-form 2.pdf

213-kol-2003-granted-form 26.pdf

213-kol-2003-granted-form 3.pdf

213-kol-2003-granted-form 5.pdf

213-kol-2003-granted-priority document.pdf

213-kol-2003-granted-reply to examination report.pdf

213-kol-2003-granted-specification.pdf

213-kol-2003-granted-translated copy of priority document.pdf

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Patent Number

225962

Indian Patent Application Number

213/KOL/2003

PG Journal Number

49/2008

Publication Date

05-Dec-2008

Grant Date

03-Dec-2008

Date of Filing

09-Apr-2003

Name of Patentee

HAUNI MASCHINENBAU AG.

Applicant Address

KURT-A.-KORBER-CHAUSSEE 8-32, 21033 HAMBURG

Inventors:

#	Inventor's Name	Inventor's Address
1	WOLFF, STEPHAN	EICHLOH 3, D-21509 GLINDE
2	HORN, SONKE	IIIENWEG 54, D-21502 GEESTHACHT

PCT International Classification Number

A24D 3/02

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	10217410.5	2002-04-18	Germany